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Subaru Impreza WRX STi 2004 Service Factory Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza WRX STi Year: 2004 Codes Chassis Code: GDB Engine Code: EJ207 👋 Introduction Market Position Positioning: High-performance, rally-bred sports sedan targeted at enthusiasts and performance-oriented drivers. Competitive Analysis Competitors: Mitsubishi Lancer Evolution, Ford Focus RS, Audi S3, BMW 3 Series (performance variants). Key Features Drivetrain: Subaru's Symmetrical All-Wheel Drive (AWD) system with Driver Controlled Center Differential (DCCD). Engine: Legendary Subaru EJ207 2.0-liter turbocharged Boxer engine with twin-scroll turbocharger. Transmission: Close-ratio 6-speed manual transmission. Suspension: Performance-tuned suspension with inverted front struts. Braking: Performance Brembo brakes. 📋 Manual Details Coverage Areas Coverage Scope: Complete service and repair for the 2004 Subaru Impreza WRX STi Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format File Format: PDF Print Quality Printability: Printable without restriction 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed component disassembly, assembly, inspection, and repair procedures for the EJ207 STi engine. Fuel System: Fuel injection system, fuel pump, injectors, fuel pressure regulator, and fuel tank service. Emission Control: Evaporative emission control system (EVAP), catalytic converter, secondary air injection system (if applicable), and emissions related diagnostics. Intake System: Intake manifold, intercooler system, air intake ducting, and related sensors. Exhaust System: Exhaust manifold, downpipe, catalytic converter, muffler, and exhaust hangers. Cooling System: Radiator, coolant hoses, water pump, thermostat, coolant reservoir, and fan assembly. Lubrication System: Oil pump, oil pan, oil filter, oil cooler, and lubrication passages. Ignition System: Spark plugs, ignition coils, ignition timing, and ECU control. Speed Control System: Cruise control system operation, diagnostics, and component replacement. Transmission Manual: Operation, disassembly, assembly, inspection, and repair of the 6-speed DCCD (Driver Controlled Center Differential) manual transmission. Transmission AWD System: Center differential, rear differential, and transfer case service and maintenance. Brakes System: Brake fluid, calipers, rotors, pads, brake lines, ABS system components, and parking brake. Suspension System: Front and rear suspension components, struts, springs, control arms, sway bars, and alignment procedures. Steering System: Power steering pump, steering rack, tie rods, and steering column. Electrical System Charging: Alternator, battery, and charging circuit diagnostics. Electrical System Starting: Starter motor and related circuitry. Electrical System Lighting: Headlights, taillights, interior lights, fog lights, and related wiring. Electrical System Instruments: Instrument cluster, gauges, warning lights, and diagnostic trouble codes (DTCs). Electrical System Audio: Radio, speakers, and amplifier systems. Body And Interior: Door panels, seats, dashboard, trim pieces, and body hardware. Climate Control: HVAC system, air conditioning, heater core, blower motor, and controls. Safety Systems: Airbag system components and SRS wiring. Procedures Included Maintenance Tasks: Oil changes, filter replacements, fluid flushes, spark plug replacement, belt inspection and replacement. Troubleshooting: Diagnostic charts, symptom-based troubleshooting, and fault code interpretation. Repair Procedures: Step-by-step instructions for component removal, repair, and reinstallation. Diagnostic Testing: Procedures for testing sensors, actuators, and electrical circuits using multimeters and diagnostic tools. Torque Specifications: Detailed torque values for all critical fasteners. Diagrams And Illustrations: High-quality diagrams and step-by-step illustrations for all procedures. Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems. Technical Depth Depth: Covers basic maintenance to complete engine and transmission overhauls, including complex diagnostics. 📊 Manual Specifications File Format Compatibility: Compatible with all versions of Windows and Mac operating systems. Reader Requirement: Requires Adobe PDF Reader. Binding Type Type: Digital Download ⚙️ Engine Specifications Primary Engine Engine Type: Horizontally-opposed (Boxer), turbocharged, intercooled, DOHC, 16-valve Displacement: 1994 cc (2.0 Liters) Bore X Stroke: 92.0 mm x 75.0 mm Compression Ratio: 8.0:1 Redline: 8000 RPM Performance Horsepower: 265 PS (261 hp; 195 kW) @ 6400 RPM Torque: 343 Nm (253 lb-ft) @ 4000 RPM Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with sequential port injection Fuel Type: Premium Unleaded Gasoline (95 RON or higher recommended) Engine Management ECU: Engine Control Unit (ECU) with specific STi tuning Turbocharger Type: Twin-scroll IHI VF37 Intercooler Type: Top-mounted air-to-air intercooler 🔧 Transmission Standard Type: 6-speed manual transmission Features Dccd: Driver Controlled Center Differential (DCCD) with manual and auto modes. Fluid Specifications Manual Transmission Fluid: Subaru Extra-S Gear Oil (75W-90 GL-5) or equivalent Fluid Capacities Manual Transmission Capacity: Approx. 2.3 liters (2.4 US quarts) 📐 Dimensions Exterior Length: 4405 mm (173.4 inches) Width: 1770 mm (69.7 inches) Height: 1410 mm (55.5 inches) Wheelbase: 2625 mm (103.3 inches) Weights Curb Weight: Approx. 1450 kg (3197 lbs) Gross Weight Rating: Approx. 1850 kg (4079 lbs) 🛡️ Safety Features Ratings NHTSA Front Impact: Not explicitly rated for this specific year/trim by NHTSA as a dedicated STi model in many markets. Standard Impreza models from this era received good ratings. IIHS Front Impact: Not explicitly rated for this specific year/trim by IIHS. Active Features ABS: Anti-lock Braking System (ABS) AWD: Symmetrical All-Wheel Drive (AWD) Dccd: Driver Controlled Center Differential (DCCD) for adjustable torque distribution. Passive Features Airbags: Front driver and passenger airbags, side airbags (optional/market dependent). Seatbelts: 3-point front and rear seatbelts with pretensioners and...
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SKU: 314900
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Subaru Impreza WRX STi 2004 Service Factory Workshop ManualSubaru Impreza WRX STi 2004 Service Factory Workshop ManualSubaru Impreza WRX STi 2004 Service Factory Workshop ManualSubaru Impreza WRX STi 2004 Service Factory Workshop Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza WRX STi
Year:
2004
Codes
Chassis Code:
GDB
Engine Code:
EJ207
👋 Introduction
Market Position
Positioning:
High-performance, rally-bred sports sedan targeted at enthusiasts and performance-oriented drivers.
Competitive Analysis
Competitors:
Mitsubishi Lancer Evolution, Ford Focus RS, Audi S3, BMW 3 Series (performance variants).
Key Features
Drivetrain:
Subaru's Symmetrical All-Wheel Drive (AWD) system with Driver Controlled Center Differential (DCCD).
Engine:
Legendary Subaru EJ207 2.0-liter turbocharged Boxer engine with twin-scroll turbocharger.
Transmission:
Close-ratio 6-speed manual transmission.
Suspension:
Performance-tuned suspension with inverted front struts.
Braking:
Performance Brembo brakes.
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete service and repair for the 2004 Subaru Impreza WRX STi
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
File Format:
PDF
Print Quality
Printability:
Printable without restriction
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed component disassembly, assembly, inspection, and repair procedures for the EJ207 STi engine.
Fuel System:
Fuel injection system, fuel pump, injectors, fuel pressure regulator, and fuel tank service.
Emission Control:
Evaporative emission control system (EVAP), catalytic converter, secondary air injection system (if applicable), and emissions related diagnostics.
Intake System:
Intake manifold, intercooler system, air intake ducting, and related sensors.
Exhaust System:
Exhaust manifold, downpipe, catalytic converter, muffler, and exhaust hangers.
Cooling System:
Radiator, coolant hoses, water pump, thermostat, coolant reservoir, and fan assembly.
Lubrication System:
Oil pump, oil pan, oil filter, oil cooler, and lubrication passages.
Ignition System:
Spark plugs, ignition coils, ignition timing, and ECU control.
Speed Control System:
Cruise control system operation, diagnostics, and component replacement.
Transmission Manual:
Operation, disassembly, assembly, inspection, and repair of the 6-speed DCCD (Driver Controlled Center Differential) manual transmission.
Transmission AWD System:
Center differential, rear differential, and transfer case service and maintenance.
Brakes System:
Brake fluid, calipers, rotors, pads, brake lines, ABS system components, and parking brake.
Suspension System:
Front and rear suspension components, struts, springs, control arms, sway bars, and alignment procedures.
Steering System:
Power steering pump, steering rack, tie rods, and steering column.
Electrical System Charging:
Alternator, battery, and charging circuit diagnostics.
Electrical System Starting:
Starter motor and related circuitry.
Electrical System Lighting:
Headlights, taillights, interior lights, fog lights, and related wiring.
Electrical System Instruments:
Instrument cluster, gauges, warning lights, and diagnostic trouble codes (DTCs).
Electrical System Audio:
Radio, speakers, and amplifier systems.
Body And Interior:
Door panels, seats, dashboard, trim pieces, and body hardware.
Climate Control:
HVAC system, air conditioning, heater core, blower motor, and controls.
Safety Systems:
Airbag system components and SRS wiring.
Procedures Included
Maintenance Tasks:
Oil changes, filter replacements, fluid flushes, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, and fault code interpretation.
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation.
Diagnostic Testing:
Procedures for testing sensors, actuators, and electrical circuits using multimeters and diagnostic tools.
Torque Specifications:
Detailed torque values for all critical fasteners.
Diagrams And Illustrations:
High-quality diagrams and step-by-step illustrations for all procedures.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems.
Technical Depth
Depth:
Covers basic maintenance to complete engine and transmission overhauls, including complex diagnostics.
📊 Manual Specifications
File Format
Compatibility:
Compatible with all versions of Windows and Mac operating systems.
Reader Requirement:
Requires Adobe PDF Reader.
Binding Type
Type:
Digital Download
⚙️ Engine Specifications
Primary Engine
Engine Type:
Horizontally-opposed (Boxer), turbocharged, intercooled, DOHC, 16-valve
Displacement:
1994 cc (2.0 Liters)
Bore X Stroke:
92.0 mm x 75.0 mm
Compression Ratio:
8.0:1
Redline:
8000 RPM
Performance
Horsepower:
265 PS (261 hp; 195 kW) @ 6400 RPM
Torque:
343 Nm (253 lb-ft) @ 4000 RPM
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with sequential port injection
Fuel Type:
Premium Unleaded Gasoline (95 RON or higher recommended)
Engine Management
ECU:
Engine Control Unit (ECU) with specific STi tuning
Turbocharger
Type:
Twin-scroll IHI VF37
Intercooler
Type:
Top-mounted air-to-air intercooler
🔧 Transmission
Standard
Type:
6-speed manual transmission
Features
Dccd:
Driver Controlled Center Differential (DCCD) with manual and auto modes.
Fluid Specifications
Manual Transmission Fluid:
Subaru Extra-S Gear Oil (75W-90 GL-5) or equivalent
Fluid Capacities
Manual Transmission Capacity:
Approx. 2.3 liters (2.4 US quarts)
📐 Dimensions
Exterior
Length:
4405 mm (173.4 inches)
Width:
1770 mm (69.7 inches)
Height:
1410 mm (55.5 inches)
Wheelbase:
2625 mm (103.3 inches)
Weights
Curb Weight:
Approx. 1450 kg (3197 lbs)
Gross Weight Rating:
Approx. 1850 kg (4079 lbs)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not explicitly rated for this specific year/trim by NHTSA as a dedicated STi model in many markets. Standard Impreza models from this era received good ratings.
IIHS Front Impact:
Not explicitly rated for this specific year/trim by IIHS.
Active Features
ABS:
Anti-lock Braking System (ABS)
AWD:
Symmetrical All-Wheel Drive (AWD)
Dccd:
Driver Controlled Center Differential (DCCD) for adjustable torque distribution.
Passive Features
Airbags:
Front driver and passenger airbags, side airbags (optional/market dependent).
Seatbelts:
3-point front and rear seatbelts with pretensioners and load limiters.
Child Anchors:
LATCH (Lower Anchors and Tethers for CHildren) system.
💡 Technology Features
Infotainment
Audio System:
Factory installed radio with CD player, AM/FM tuner, and speaker system.
Display:
Digital odometer and basic instrument cluster displays.
Driver Assistance
AWD Control:
Advanced AWD system with DCCD for torque vectoring.
Connectivity
N/A:
Limited connectivity features typical of vehicles from this era; no Bluetooth or USB connectivity from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, depending on driving conditions (severe use recommended for spirited driving).
Engine Oil Type:
API SG or higher, SAE 5W-30 or 10W-30 synthetic oil recommended.
Oil Filter Part Number:
Subaru OEM: 15208AA031 or aftermarket equivalent (e.g., Wix 57055, K&N HP-1010)
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 5 years. Critical due to interference engine design.
Coolant Type:
Subaru Genuine Coolant (Blue) or equivalent ethylene glycol-based coolant with corrosion inhibitors (50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Fluid Specifications
Power Steering Fluid:
Subaru Genuine ATF or Dexron II/III compatible fluid.
Known Issues
Piston Ring Land Failure:
Known issue in some EJ207 engines, particularly when modified or subjected to high stress. Manual addresses inspection and prevention.
Clutch Wear:
Can wear faster than average due to performance nature of the vehicle. Manual provides inspection and replacement procedures.
Turbocharger Wear:
Turbocharger may require rebuilding or replacement over time; manual details inspection and maintenance.
Suspension Bushings:
Wear on suspension bushings can affect handling; manual guides replacement.
📚 Vehicle History
Brand Heritage
Rally Connection:
Subaru's extensive World Rally Championship (WRC) heritage, with the Impreza WRX STi being the road-going homologation version of its rally cars.
Model Evolution
Generation:
Second Generation (GD) Subaru Impreza, specifically the 'Bugeye' to 'Blobeye' transition year.
Ej207 Significance:
The EJ207 engine is highly regarded for its performance tuning potential and robust construction, often sought after by enthusiasts.
Production
Production Years:
2000-2007 (Second Generation GD)
Manufacturing Location:
Gunma Plant, Japan
🏆 Awards & Recognition
Recognitions
Rally Performance:
Consistently recognized for its rally-bred performance and handling capabilities.
Enthusiast Following:
Maintains a strong and dedicated enthusiast following for its tuning potential and driving dynamics.
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